Yarn carrier

ABSTRACT

A yarn carrier is provided in the form of a yarn winding tube having a yarn catch insert. The yarn winding tube is a hollow cylindrical tube having a longitudinal axis extending lengthwise between its first and second opposite ends. The tube has a hole through its surface for receiving a yarn catch insert. The yarn catch insert includes a first member and a second member, each having an inside surface. When positioned within the hole, the inside surfaces of the first and second members face each other and form a string-up groove therebetween. After a yarn winding and unwinding process, the yarn catch insert may be removed from the hole in the tube, the first and second member may be separated, and the string-up groove may be cleaned. The yarn catch insert may then be re-inserted into the hole and the tube may be reused for winding.

RELATED APPLICATIONS

The present application claims the benefit of U.S. patent applicationSer. No. 10/685,976, filed Oct. 14, 2003, the entire contents of whichare incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to a yarn carrier and, in particular, to ayarn carrier having a cleanable pick-up groove for high speed windingoperations.

BACKGROUND OF THE INVENTION

Textile yarn cores, i.e., yarn winding tubes, yarn carriers or bobbins,are employed in the textile industry for winding and supporting yarnpackages. In the package forming process, a moving yarn line is strungup onto a rapidly rotating empty core. The moving yarn line is broughtinto tangential contact with the rotating empty core. Typically, astart-up (or pick-up) groove is provided in the surface of the core,normally adjacent one end of the core. The yarn line is directed intothe groove which grips and breaks the yarn line, thereby initiating thewind-up process.

Multiple width start-up grooves in yarn cores have been provided in aneffort to improve the yarn pick up propensities of the groove. In themultiple width pick up grooves, one longitudinal, i.e., lengthwise,portion of the groove is relatively wide while an adjacent longitudinalportion is relatively narrow. The core is rotated so that the wideportion of the groove forms the leading portion; the narrow portion ofthe groove forms the trailing portion. The transition portion of thegroove, between the wide and narrow portions, then forms a “nip” forgripping and catching the yarn. The initial strands of the yarn that arecaught by the groove during the initial few turns of the automaticwinding operation are commonly referred to as the “transfer bunch.” Whenthe yarn is removed from the package, the last few strands of thetransfer bunch often remain in the groove.

The string-up efficiency, defined as the percentage of successfulstring-ups over time as compared to the total attempted number ofstring-ups, is reduced with repeated use of a yarn winding tube. Thisreduction is partly due to the compression of the fiber fibrils of apaper tube, for example, that assist in the catching of the yarn andwhich are further damaged when the transfer bunch is removed from thegroove. The efficiency reduction is also partly due to the portion ofthe transfer bunch that remains in the groove and diminishes the abilityof the groove to further catch yarn.

A missed string-up, even in one yarn carrier, results in a significantloss of production, since yarn carriers are used in multiple carrierwinders (e.g., 2, 4, . . . 10) per shaft. A missed string-up requireshuman intervention in re-stringing up of the position, sometimesrequiring wiping of the spinneret face. When one in a gang of yarncarriers fails to string-up, this process may result in a loss of 10-30minutes of production time.

It is desirable to reduce manufacturing costs by maintaining a highstring-up efficiency and to reduce part costs by re-using yarn carriertubes. These are often conflicting goals because the string-upefficiency of a tube deteriorates with repeated use of a yarn carriertube due to damage cause by removal of yarn from the groove and due toyarn remaining in the groove.

It is often difficult to remove all the remaining strands of thetransfer bunch from the groove without damaging the tube, especiallywhen the tube is made of paper. This is because typical yarn catchinggrooves are very difficult to clean due to the very tight grip impartedby the walls of the groove on the yarn. Removal of the yarn usuallyresults in broken filaments being retained in the groove.

One method of removing yarn from the groove, vacuuming, may not damagethe tube but typically does not remove all the yarn from the groove. Asthe carrier is reused, accumulation of broken filaments and walldeterioration increases, further decreasing string-up efficiency. Othermethods, such as using a knife to clean the groove, may remove thetransfer bunch from the groove but may also damage the surface of thetube or the groove, thereby making the tube unsuitable for further use.

Reuse of the groove is thus limited due to the deterioration of thegroove surface and to the collection therein of broken filaments. As aresult, yarn carriers are often discarded with little or no reuse ratherthan incur the increased cost of production that results from a lowstring efficiency.

SUMMARY OF THE INVENTION

According to the present invention, there is provided a yarn carrier forwinding yarn thereon. The yarn carrier includes a hollow cylindricaltube having a longitudinal axis extending lengthwise between first andsecond opposite ends thereof and having a substantially cylindricalouter surface. The tube has a recess formed into the first end. Therecess has an inside surface with first and second ends, and a firstrecess side surface extending from the first end of the inside surfaceto the first end of the tube. A yarn catch insert is adapted to beinserted into the recess. The yarn catch insert has an inside surfacewith first and second ends, an outside surface, and a first side surfaceextending between the first end of the inside surface and its outsidesurface. When the yarn catch insert is inserted into the recess, theinside surface of the yarn catch insert is positioned opposite theinside surface of the recess and the distance between the inside surfaceof the recess and the inside surface of the yarn catch insert tapersalong at least a portion of the inside surface of the recess.

According to another aspect of the invention, there is provided a yarncatch insert for insertion into a hole formed through a yarn windingtube. The yarn winding tube is a hollow cylindrical tube having alongitudinal axis extending lengthwise between first and second oppositeends thereof and having a substantially cylindrical outer surface. Thehole in the tube has a side surface with a portion extendingcircumferentially around a portion of the circumference of the tube. Theyarn catch insert has an inside surface, and outside surface, and a sidesurface, a portion of the side surface is positioned opposite theportion of the side surface of the hole when the insert is inserted intothe hole to form a start-up groove between the portion of the sidesurface of the yarn catch insert and the portion of the side surface ofthe hole. At least a portion of the start-up groove is tapered in adirection along the circumference of the tube.

According to another aspect of the invention, there is provided a yarncatch insert having a first member and a second member. The first memberhas a first end, an opposite second end, and an inner surface. Thesecond member has a first end, an opposite second end, and an innersurface. The first and second members are adapted to be inserted into ahole in a yarn winding tube such that their respective inner surface arepositioned opposite each other. The distance between the inner surfacestapers along at least a portion of the inner surfaces to form a start-upgroove.

According to a further aspect of the invention, there is provided a yarncarrier for winding yarn thereon. The yarn carrier includes a hollowcylindrical tube having a longitudinal axis extending lengthwise betweenfirst and second opposite ends thereof. The tube has substantiallycylindrical inner and outer surfaces and a non-symmetrical hole formedtherein for accepting a yarn catch insert.

According to a still further aspect of the invention, there is provideda yarn carrier for winding yarn thereon. The yarn carrier includes ahollow cylindrical inner tube and a hollow cylindrical outer tube. Eachtube has a longitudinal axis extending lengthwise between first andsecond opposite ends thereof, a substantially cylindrical outer surface,and a hole formed through the tube. The inner tube is disposed withinthe outer tube so that the holes in the inner and outer tubes aresubstantially aligned for receiving a yarn catch insert.

According to yet another aspect of the invention, there is provided ayarn carrier for winding yarn thereon. The yarn carrier includes ahollow cylindrical tube and a ring. The tube has an external annularchannel adjoining one end of the tube, the channel having a base surfaceradially inward of the outer surface of the tube. A shoulder is formedbetween the outer surface of the tube and the base surface of thechannel. The shoulder extends substantially radially inward from theouter surface of the tube to the base surface of the channel. A recessin the shoulder extends around a portion of the tube circumference andhas an inside surface. The ring is adapted to be removably retainedwithin the channel. The ring has a ring engagement surface positionedadjacent the shoulder when the ring is retained within the firstchannel. The ring engagement surface has a protrusion coinciding withthe recess in the shoulder and having a surface cooperating with theinside surface of the recess to form a tapered groove for engaging theyarn during winding startup.

According to yet another aspect of the invention, there is provided ayarn carrier for winding yarn thereon. The yarn carrier includes innerand outer hollow cylindrical tubes and a ring. The inner and outer tubeseach have substantially cylindrical inner and outer surfaces, a firstend, an opposite second end, and inner and outer surfaces therebetween.The outer diameter of the inner tube is slightly less than the innerdiameters of the outer tube and ring so the inner tube may be tightlycoupled within the outer tube and ring. A recess is formed in the firstend of the outer tube. The ring has a first end surface and a second endsurface, the first end surface adjoining the first end of the innertube, the second end surface having a protrusion coinciding with therecess in the outer tube and having a surface cooperating with theinside surface of the recess to form a tapered groove for engaging theyarn during winding startup.

According to yet another aspect of the invention, there is provided anapparatus for forming a hole in a hollow cylindrical tube. The apparatusincludes a die having an opening formed therein for receiving a punchand having an outer surface that substantially matches the curvature ofat least a portion of the inner surface of the tube. The outer surfaceof the die extends radially outward in the vicinity of and as itapproaches the opening in the die. When a hole is punched into the tubeby placing the die in the tube and then inserting the punch through thetube and into the opening in the die, a countersink is formed on theinner surface of the tube adjacent to the hole formed in the tube.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a yarn carrier according to the presentinvention;

FIG. 2 is a side elevation view of the yarn carrier shown in FIG. 1;

FIG. 3A is a top view of the yarn carrier shown in FIG. 1 with its yarncatch insert in an open position;

FIG. 3B is a top view of the yarn carrier shown in FIG. 1 with its yarncatch insert in a closed position;

FIG. 4 is a top view of an assembled yarn carrier according to anotherembodiment of the present invention;

FIG. 5 is an exploded top view of the yarn carrier shown in FIG. 4;

FIG. 6 is a cross-sectional view of the yarn carrier of FIG. 4 takenalong the line 6-6;

FIG. 7 is a top view of an assembled yarn carrier according to anotherembodiment of the present invention;

FIG. 8 is an exploded top view of the yarn carrier shown in FIG. 7;

FIG. 9 is a cross-sectional view of the yarn carrier of FIG. 7 takenalong the line 9-9;

FIG. 10 is a cross-sectional view of the yarn carrier of FIG. 7 takenalong the line 10-10;

FIG. 11 is a top view of an assembled yarn carrier according to anotherembodiment of the present invention;

FIG. 12 is an exploded top view of the yarn carrier shown in FIG. 11;

FIG. 13 is a cross-sectional view of the yarn carrier of FIG. 11 takenalong the line 13-13;

FIG. 14 is an exploded isometric view of a yarn carrier according toanother embodiment of the present invention;

FIG. 15 is a top view of the yarn carrier shown in FIG. 14 having itsyarn carrier insert positioned within the yarn carrier tube;

FIGS. 16-18 are cross-sectional views of the yarn carrier of FIG. 15taken along the lines 16-16, 17-17, and 18-18, respectively;

FIG. 19A is an isometric view of the yarn carrier according to anotherembodiment of the present invention having a yarn carrier insertpositioned within the yarn carrier tube that comprises an inner core andan outer sleeve;

FIG. 19B is a cross-sectional view of the yarn carrier of FIG. 19A takenalong the line 19B-19B;

FIG. 20 is an exploded isometric view of a yarn carrier according toanother embodiment of the present invention;

FIG. 21 is a top view of a portion of the yarn carrier shown in FIG. 20having its yarn carrier insert positioned within the yarn carrier tube;

FIGS. 22-24 are cross-sectional views of the yarn carrier of FIG. 21taken along the lines 22-22, 23-23, and 24-24, respectively;

FIG. 25 is an exploded isometric view of an apparatus according to thepresent invention for forming a hole in a yarn winding tube;

FIG. 26 is a cross-sectional view of the apparatus of FIG. 25 takenalong the line 26-26 with the punch positioned in the die after punchinga hole through a tube;

FIG. 27 an isometric view of the yarn carrier according to anotherembodiment of the present invention having a yarn capturing groovepositioned within the inner core of a composite yarn carrier tube;

FIG. 28 is a cross-sectional view of the yarn carrier of FIG. 27 takenalong the line 27; and

FIG. 29 is an exploded isometric view of a yarn carrier according toanother embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings, in which like reference numerals illustratecorresponding or similar elements throughout the several views, there isshown in FIG. 1 an isometric view of a yarn carrier 100 for winding yarnthereon according to an exemplary embodiment of present invention.

The yarn carrier 100 includes a hollow cylindrical tube 102 and a yarncatch insert 104. The tube 102 has a first end 106, an opposite secondend (not shown), and a longitudinal axis extending lengthwise betweenthe first and second ends. The outer surface 108 of the tube 102 issubstantially cylindrical.

A recess 110 is formed into the first end 106 of the tube 102. Therecess 110 has an inside surface 112 with a first end 114, a second end116, and a first recess side surface 118 that extends from the first end114 of the inside surface 112 to the first end 106 of the tube 102. Theyarn catch insert 104 flexibly extends from the tube 102 whereby it maybe removably inserted into the recess 110. The yarn catch insert 104 maymove between an “open” position as shown in FIGS. 1 and 3A where theyarn catch insert 104 is not within the recess 110 and a “closed”position as shown in FIG. 3B where the yarn catch insert 104 ispositioned in the recess 110.

The yarn catch insert 104 has an inside surface 120 with first end 122and a second end 124, an outside surface 126, and a first side surface128 extending between the first end 122 of the inside surface 120 andits outside surface 130. When the yarn catch insert 104 is in the closedposition, a start-up groove 132 is formed between the inside surface 112of the recess 110 and the inside surface 120 of the yarn catch insert104. The yarn carrier 100 may then be used for winding operations.

As shown in FIG. 3B, when the yarn catch insert 104 is inserted into therecess 110 (i.e., the “closed” position), the inside surface 120 of theyarn catch insert 104 is positioned opposite the inside surface 112 ofthe recess 110 and the distance D between the inside surface 112 of therecess 110 and the inside surface 120 of the yarn catch insert 104tapers to a pinch point 146. As the tube 102 rotates in the direction ofarrow R, yarn that is directed into the groove 132 is gripped by thegroove 132 to initiate the wind-up process. In the exemplary embodimentshown in FIGS. 1-3, the inside surface 112 of the recess 110 and theinside surface 120 of the yarn catch insert 104 are substantiallyperpendicular to the longitudinal axis of the tube 102.

After previously-wound yarn is unwound from the yarn carrier 100, theyarn catch insert 104 may be removed from the recess (i.e., moved intothe open position) to open up the start-up groove 132 for removal of anyfibers from the start-up groove 132. The ability to open the start-upgroove 132 allows any yarn “stuck” in the start-up groove 132 to beremoved without damage to the start-up groove 132. After cleaning thestart-up groove 132, the yarn catch insert 104 may then be restored tothe closed position and the yarn carrier 100 may be reused whilemaintaining a high string-up efficiency because the ability of thestart-up groove 132 to catch yarn is not diminished because anypreviously-stuck fibers have been removed.

Yarn may be wound at a rate of 5000-6000 meters/minute, for example. Thecorresponding rate of rotation of the tube, in order to maintain thewinding rate, causes the yarn catch insert 104 to exert a centrifugalforce that must be opposed to prevent the yarn catch insert 104 fromextending radially outward of the outer surface 108 of the tube 102. Inthe exemplary embodiment shown in FIGS. 1-3, the yarn catch insert 104is removably securable to the tube 102 using a combination of a shelf134 and teeth 136.

The shelf 134 is positioned radially inward of and extends under theouter surface 108 of the tube 102 when the yarn catch insert 104 is inthe closed position. The tube 102 includes a channel 138 formed in thefirst recess side surface 118 for receiving the shelf 134 of the yarncatch insert 104 when in the closed position. The lower surface of thechannel 138 exerts a centripetal force upon the shelf 138 in a directiontoward the center of rotation to prevent the yarn catch insert 104 fromextending radially outward of the outer surface 108 of the tube 102.

The teeth 136, 140 on the first side surface 128 of the yarn catchinsert 104 and/or on the first side surface 118 of the recess 110 areused to removably secure the yarn catch insert 104 in the recess 110. Toclose the yarn catch insert 104 from an open position, the teeth 136,140 may be flexible and the yarn catch insert may be rotated in adirection parallel to the longitudinal axis of the tube 102 to engagethe teeth 136, 140. To facilitate rotation of the yarn catch insert 104from the open to closed position, voids 142, 144 are formed in the yarncarrier at the second end 116 of inside surface 112 of the recess 110and in the outside surface 130 of the yarn catch insert 104. The voidsincrease the flexibility of the junction where the insert 104 extendsfrom the tube 102. To open the yarn catch insert 104 from a closedposition, the yarn catch insert 104 may be pressed axially inward todisengage the teeth 136, 140 as illustrated by the phantom lines in FIG.2.

Although the start-up groove 132 illustrated in FIG. 3 is designed forcatching yarn when the tube 102 is rotated in direction R, the tube 102may be bi-directionally operable by having a portion of the start-upgroove 132 taper in direction R and a different portion of the start-upgroove widen in the same direction R. Also, more than one yarn catchinsert 104 and recess 110 combination may be formed on one or both endsof the tube 102. One yarn catch insert and recess may have a start-upgroove for winding yarn when rotated in direction R and another yarncatch insert and recess may have a start-up groove for winding yarn whenrotated in the opposite direction.

The yarn carrier 100 does necessarily require teeth 136, 140 forsecuring the yarn catch insert 104 in the recess 110. The yarn catchinsert 104 may be secured in the recess 110 by placing the yarn carrier100 upon a spindle for winding that has an end cap or other form ofstop. When the tube 102 is pressed and secured against the stop, theyarn catch insert 104 is moved or forced from the open to closedposition by positioning the tube 102 against the stop. Alternatively,the yarn catch insert 104 may be permanently bonded within the recess102 by sonic welding, for example. The yarn carrier 100 may be made ofpolypropylene, nylon, or other polymers and may be formed by molding,for example. The yarn catch insert 104 may be molded into anormally-open position and then pressed into its closed position asneeded for winding operations.

Permanently bonding the yarn catch insert 104 into the recess 110diminishes its re-usability because the start-up groove 132 can not beopened for cleaning. However, it still provides improved performanceover a yarn carrier with a one-piece molded start-up groove because itis difficult to mold a one-piece start-up groove with sidewallsperpendicular to the longitudinal axis or with a pinch point.

Although the yarn catch insert 104 in FIGS. 1-3 is illustrated asextending from the tube 102, in another exemplary embodiment, the yarncatch insert 104 is separate from the tube 102. The separate yarn catchinsert 104 may then have teeth and/or a shelf on both ends for secureattachment to the tube 102.

A yarn carrier 400 according to another embodiment of the presentinvention is shown in FIGS. 4-6. The yarn carrier 400 includes a hollowcylindrical tube 402 and a resilient ring 404. The ring 404 and the tube402 are designed to be removably secured to each other, forming astart-up groove 430 between their respective surfaces. After winding andunwinding yarn from the carrier 400, the ring 404 may be removed fromthe tube 402 to open up the start-up groove 430 and remove of any yarnretained in the groove 430.

The tube 402 has a first end 406, an opposite second end (not shown),and a longitudinal axis extending lengthwise between the first andsecond ends. The outer surface 408 of the tube is substantiallycylindrical. An external annular channel 410 adjoins the first end 406of the tube 402. The channel 410 has a base surface 412 that is radiallyinward of the outer surface 408 of the tube 402 with a shoulder 414formed between the outer surface 408 of the tube 402 and the basesurface 412 of the first channel 410. The shoulder 414 extendssubstantially radially inward from the outer surface 408 of the tube 402to the base surface 412 of the channel 410. A recess 416 is formed inthe shoulder 414, extends around a portion of the tube circumference,and has an inside surface 424.

The resilient ring 404 is adapted to be removably retained within thechannel 410. The ring 404 may be retained within the channel 410 by afriction fit, or by other attachment mechanisms such as ribs on thechannel surface 412 corresponding to ruts in the inside surface of thering 404. The ring 404 has a ring engagement surface 418 positionedadjacent to the shoulder 414 when the ring 404 is retained within thechannel 410. The ring 404 has a first end surface adjoining the firstend of the tube adjacent the first channel.

The ring engagement surface 418 has a protrusion 420 coinciding with therecess 416 in the shoulder 414 of the tube 402. The protrusion 420 has aside surface 422 cooperating with the inside surface 424 of the recess416 to form a tapered start-up groove for engaging the yarn duringwinding start-up.

A score 426 is formed in the tube 402 to help direct the yarn into thestart-up groove during winding operations. The score 426 may be formedby applying pressure around the circumference of the tube 402 with arotary tool. The score 426 is formed in the outer surface 408 of andextends around the circumference of the tube 402. The apex 428 of thescore 426 intersects the inside surface 424 of the recess 416.

A yarn carrier 700 according to another embodiment of the presentinvention is shown in FIGS. 7-10. The yarn carrier 700 includes an innerhollow cylindrical tube 702, a outer hollow cylindrical tube 704, and aresilient ring 706. The outer tube 704 and ring 706 are designed to beremovably secured adjacent to each other and upon the inner tube 702,forming a start-up groove 726 between their respective surfaces. Afterwinding and unwinding yarn from the carrier 700, the ring 706 and/orouter tube 704 may be removed from the inner tube 702 to open up thestart-up groove 726 and remove of any yarn retained in the groove 726.

The outer tube 704 and the ring 706 have inside diameters larger thanthe outside diameter of the inner tube 702 so the inner tube 702 may bepositioned within the outer tube 704 and ring 706. The start-up groove726 is formed between the end surfaces of the outer tube 704 and ring706, extending partially around the circumference of the yarn carrier700. In the embodiment shown in FIG. 7-10, the taper of the start-upgroove 726 is formed by the cooperation of a recess formed in the sidewall of the ring 706 and the side wall of the tube 704.

The inner tube 702 and outer tube 704 each have a first end, an oppositesecond end, and a longitudinal axis extending lengthwise between theirrespective first and second ends. The inner tube 702 has a substantiallycylindrical outer surface 708 and an outer diameter measured from thecenter of the tube to the outside surface 708 of the inner tube 702. Theouter tube 704 has a substantially cylindrical inner surface 710, aninner diameter measured from the center of the tube to the insidesurface 710 of the outer tube 704, and a recess 720 formed in its firstend 722. The inner and outer tubes 702, 704 are manufactured so theinner diameter of the outer tube 704 is slightly greater than the outerdiameter of the inner tube 704 so the inner tube may be tightlypositioned within the outer tube.

The ring 706 has a first end surface 712 and a second end surface 714.The first end surface 712 adjoins the first end 716 of the inner tubeand the second end surface 714 has a protrusion 718 coinciding with therecess 720 in the outer tube. The yarn carrier 700 may be assembled byplacing the inner tube 702 within the outer tube 704 and then slidingthe ring 706 onto the first end 716 of the inner tube 702 oriented soits protrusion 718 aligns with the recess 720 in the outer tube 704. Theprotrusion 718 secures the outer tube 704 and the ring 706 so theyrotate in unison.

A score 724 is formed in the carrier 700 to help direct the yarn intothe start-up groove 726 during winding operations. The score is formedin the outer surface of and extends around the circumference of thecarrier 700. The apex 728 of the score 724 coincides with the pinchpoint of the start-up groove 726. The second end 714 of the ring 706 andthe first end 716 of the outer tube 704 are tapered radially inward totogether form the score 724.

In an exemplary embodiment, one or more of the inside surface of theouter tube 704, the inside surface of the ring 706, or the outsidesurface of the inner tube 702 have ribs for securing the ring and outertube to the inner tube by press fitting, for example. In an exemplaryembodiment, the outer tube 704 is made of paper and the inner tube 702and ring 706 are made of plastic. Although the embodiment shown in FIGS.7-10 has a recess and protrusion formed in the side wall of the ring706, one or both of the recess and protrusion could similarly be formedin the ring 704.

Another yarn carrier 1100 according to the present invention is shown inFIGS. 11-13. The yarn carrier 1100 includes an inner hollow cylindricaltube 1102, an outer hollow cylindrical tube 1104, and a resilient ring1106.

The outer tube 1104 and ring 1106 are designed to be removably securedadjacent to each other and upon the inner tube 1102, forming a start-upgroove 1108 between their respective surfaces. After winding andunwinding yarn from the carrier 1100, the ring 1106 and/or outer tube1104 may be removed from the inner tube 1102 to open up the start-upgroove 1108 and remove of any yarn retained in the groove 1108.

The outer tube 1104 and the ring 1106 have inside diameters larger thanthe outside diameter of the inner tube 1102 so the inner tube 1102 maybe positioned within the outer tube 1104 and ring 1106. In contrast tothe yarn carrier 700 shown in FIGS. 7-10, the start-up groove 1108 ofthe yarn carrier 1100 is not formed at the intersection of the sidesurfaces of the outer tube 1104 and the ring 1106. The start-up groove1108 is formed at the intersection of the side surface 1120 of therecess 1110 of the outer tube 1104 and the side surface 1122 of aprotrusion 1112 of the ring 1106. The start-up groove 1108 extendspartially around the circumference of the yarn carrier 1100.

A score 1114 is formed in the outer surface 1116 of and extends aroundthe circumference of the outer tube 1104. The apex 1118 of the score1114 coincides with the pinch point of the start-up groove 1108.

A yarn carrier 1400 according to another embodiment of the presentinvention is shown in FIGS. 14-18. The yarn carrier 1400 includes asubstantially cylindrical yarn winding tube 1402 and a yarn catch insert1404 for insertion through a hole 1406 in the tube 1402. Preferably, theinsert 1404 is inserted into the hole 1406 from the inside of the tubeas shown in FIG. 14.

The shape of the hole 1406 and the shape of the insert 1404 are designedto form a tapered string-up groove 1408 between a surface of the insert1404 and a sidewall of the hole 1406. Preferably, the yarn catch inserthas a flange (not shown) on its bottom surface to prevent the topsurface 1410 of the insert 1404 from extending past the outer surface1412 of the tube 1402 during winding operations. After winding andunwinding of yarn from the carrier 1400, the insert 1404 may be removedfrom the tube 1402 by pressing it into the center of the tube 1402. Thestart-up groove is thereby taken apart and any remaining yarn may beremoved. The same or a different insert 1404 may then be re-insertedinto the hole 1402 of the same or a different tube 1402 for re-use.

The yarn winding tube 1402 is a hollow cylindrical tube having alongitudinal axis extending lengthwise between first and second oppositeends thereof and having a substantially cylindrical outer surface 1412.The hole 1406 has a side surface 1418 with a first portion 1420extending circumferentially around a first portion of the circumferenceof the tube 1402. The yarn catch insert 1404 has a bottom surface 1422,a top surface 1412, and a side surface 1424.

A first portion 1424 a of the side surface 1424 of the insert 1404 ispositioned opposite the first portion 1418 a of the side surface 1418 ofthe hole 1406 when the insert 1404 is inserted into the hole 1406 toform the start-up groove 1408 between the first portion 1424 a of theside surface 1424 of the yarn catch insert 1404 and the portion 1418 aof the side surface 1418 of the hole 1406. In an exemplary embodiment,the side surfaces 1418 a, 1424 a of the insert 1404 and the side surfaceof the hole 1406 meet or come within a distance of each other that isless than the thickness of the yarn to be wound to form a pinch point tograb the yarn. As shown in FIGS. 16-18, the first portion 1418 a of theside surface 1418 of the hole 1406 and the first portion 1424 a of theside surface 1424 of the yarn catch insert 1404 are perpendicular to thelongitudinal axis of the tube.

The yarn catch insert 1404 is curved to match the curvature of the tube1402 and has a lower portion 1404 a and an upper portion 1404 b. Thelower portion 1404 a has a width corresponding to the width of the holein the tube for a tight fit to secure the insert 1404 in the hole 1406.The upper portion 1404 b has a width less than the width of the hole1406 in the tube 1402. The start-up groove 1408 is formed in the spacebetween the upper portion 1404 b of the insert 1404 and the side wall1418 a of the hole 1406. The yarn catch insert 1404 may be comprised ofmaterials including plastic, wood, and metal.

As illustrated in FIGS. 15-18, the edges at the top surface 1412 of theinsert 1404 are radiused. The radiused edges adjacent to the side walls1418 of the hole 1406 facilitate insertion of the insert 1404 into thehole 1406. The radiused edges adjacent to the start-up groove 1408facilitate directing yarn into the start-up groove 1408.

A score 1414 is formed in the outer surface 1412 of and extends aroundthe circumference of the tube 1402. The apex 1416 of the score coincideswith the pinch point of the start-up groove 1408.

A yarn catch insert according to the present invention may be used withyarn carriers that include multiple layers of concentric winding tubes.An exemplary yarn carrier 1900 having multiple layers of winding tubesis shown in FIGS. 19A-B. The yarn carrier 1900 includes an inner tube orcore 1902, an outer tube or sleeve 1904, and a yarn catch insert 1906.The outer tube 1904, made of paper, for example, is placed on the innertube 1902, made of plastic or metal, for example, to form a compositeyarn carrier into which is inserted an insert 1906 in which a yarncatching mechanism has been molded and/or machined. This compositedesign allows for the independent replacement of outer and inner tubesas each wears with repeated use.

The inner tube 1902 and outer tube 1904 each have a first end, anopposite second end, and a longitudinal axis extending lengthwisebetween their respective first and second ends. The inner tube 1902 hasa substantially cylindrical outer surface 1908 and an outer diametermeasured from the center of the tube to the outside surface 1908 of theinner tube 1902. The outer tube 1904 has a substantially cylindricalinner surface 1910 and an inner diameter measured from the center of thetube to the inside surface 1910 of the outer tube 1904. Similar to theyarn carrier described above with reference to FIGS. 14-18, a portion ofthe side surface of the insert 1906 and a portion of the side surface ofthe hole cooperate to form a start-up groove 1922 for gripping yarnduring start-up of a winding operation and the insert 1906 may beremoved to clean the groove 1922. The yarn catch insert 1906 has abottom surface 1912 comprising a flange 1914 for preventing the topsurface 1916 of the yarn catch insert 1906 from extending radiallybeyond the top surface 1918 of the outer tube 1904 during windingoperations.

The inner and outer tubes 1902, 1904 are manufactured in a manner totightly positioned them against each other. This may be accomplished bya combination of precise selection of diameters, a selection ofmaterials, and/or use of mechanical connection via ribs or an adhesive,for example. The diameters may be selected so the inner diameter of theouter tube 1904 is just slightly greater than the outer diameter of theinner tube 1904 to achieve a tight fit. Ribs on one or both of the tubesmay provide a tight fit between the tubes. In an exemplary embodiment,the inner tube 1902 includes ribs on its outer surface 1908 and thecomposition of the outer tube is soft enough to absorb the ribs yetsufficiently stiff to provide a tight fit between the tubes 1902, 1904.The composition of the outer tube 1904 may vary along its thickness toprovide for a soft inner portion to allow the ribs to bite into theinner tube 1902 and have a stiffer outer portion to resist outerdimensional changes when wound with yarn.

The varying composition provides an added benefit of protecting theinner tube 1902 from deformation. When yarn is wound on the carrier1900, the radially inward pressure applied against the outer tube 1904by the wound yarn might otherwise be transferred from the outer tube1904 to the inner tube 1902 and thereby deform the inner tube 1902. Thispressure may be caused by the shrinkage of yarn after the POY processdue to thermal and/or molecular shrinkage from polymer crystallization.

If deformed, this would reduce the useful life of the inner tube 1902.This pressure may permanently damage the inner tube 1902 so that it maynot be reused and/or shrink its inside diameter so, after winding, itsticks to the spindle. However, with an outer tube 1904 having avariable composition (soft inside, stiff outside), as the outer tube1904 deforms, its softer inner composition will deform (i.e., crush) toa certain extent to reduce the transfer of force from the outer tube1904 to the inner tube 1902. In other words, the ribs and soft innerportion of the outer tube 1904 allow a reduction of the outer diameterof the yarn carrier 1900 while not deforming the inner tube 1902 orreducing its inside diameter. This also provides an added benefit forthe yarn that has been would no the carrier 1900. As the force appliedby the winding is relieved by deformation of the outer paper tube 1904,the yarn is relaxed and less stressed.

As shown in FIG. 19B, holes in each of the inner and outer tubes 1902,1904 are aligned for accepting the yarn catch insert 1906. The bottom ofthe hole in the inner tube 1902 includes a countersink 1920 foraccepting the flange 1914 of the yarn catch insert 1906. The insert 1906extends through the hole in both the inner and outer tubes 1902, 1904,thereby locking them together so they rotate in unison. Yarn may bewound at a rate of 5000-6000 meters/minute—providing only a fraction ofa second to grab the yarn and attach it to the start-up groove. If, atthat moment when the yarn is grabbed, the inner tube 1902 movesseparately from the outer tube 1904 (e.g., outside keeps turning withyarn while inside turns the opposite way), the catch of yarn may beprevented. Further, any resulting slack in the yarn resulting from theseparate movement may cause the yarn to slip or jerk when the yarn doesget caught and can break the yarn or filament or may result innon-uniform yarn denier.

A yarn carrier 2000 according to another exemplary embodiment of thepresent invention is shown in FIGS. 20-23. The yarn carrier 2000includes a yarn winding tube 2002 and a yarn catch insert 2004. The yarnwinding tube 2002 is a hollow and substantially cylindrical tube havinga longitudinal axis extending lengthwise between first and secondopposite ends thereof. The tube 2002 has a substantially cylindricalouter surface 2006 and has a hole 2008 extending through its outersurface to its center.

As shown in FIG. 20, the hole in the tube is asymmetrical which ensuresproper orientation of the insert 2004 with respect to the direction ofrotation of a winding operation. The shape of the hole in the tube inFIG. 20 resembles a baseball bat with a bulbous head on one end leadingto a longitudinal section that widens as it extends from the bulboushead. The direction of rotation of the tube 2002 for winding isindicated by arrow R in FIG. 20. The insert 2004 includes a first member2010 and a second member 2012 that form a start-up groove 2014therebetween when inserted into the hole 2008. The insert 2004 may beremoved and the first and second members 2010, 2012 separated to cleanany yarn from inside the start-up groove 2014.

The yarn catch insert 2004 is adapted to be inserted into the hole 2008from the inside of and through the yarn winding tube 2002. The insert2004 includes a first member 2010 and a second member 2012 that may becoupled together by a tether, for example. The first member 2010 has afirst end 2016, a second end 2018 opposite the first end, and an innersurface 2020. The second member 2012 has a first end 2022, a second end2024, and an inner surface 2026 facing the inner surface 2020 of thefirst member 2010 when the first and second members 2010, 2012 arepositioned in the hole 2008.

The start-up groove 2014 is formed between the inner surfaces 2020, 2026of the first and second members 2010, 2012 of the insert 2004. To formthe yarn carrier 2000, the first and second members 2010, 2012 areplaced adjacent to each other so their respective inner surfaces 2020,2026 face each other and the insert 2004 is then inserted into the hole2008 in the winding tube 2002. As illustrated by the cross-sectionalview of FIGS. 22-24, the start-up groove 2014 is tapered to a pinchpoint 2028. The start-up groove 2014 includes a barb 2026 extending fromthe inner surface 2020 of the first member 2010 into the start-up groove2014 and toward the inner surface 2026 of the second member 2012. In anexemplary embodiment, the barb 2026 extends greater than half thedistance between the inside surfaces 2020, 2026 of the first and secondmembers 2010, 2012. In another embodiment (not shown), a hook mayinstead extend from the first surface 2020 of the first member 2010 intothe start-up groove 2014.

The yarn catch insert 2004 has a bottom surface 2030 comprising a flange2032 for preventing the top surface 2034 of the yarn catch insert 2004from extending radially beyond the top surface 2006 of the tube 2002during winding operations when the tube 2002 is spinning. As shown inFIGS. 22-24, the bottom of the hole 2008 in the inner tube includes acountersink 2036 for accepting the flange 2032 of the yarn catch insert2004. Alternatively, the side walls of the hole 2008 may be tapered in adirection from the inside to the outside of the tube 2002 and theoutside walls of the yarn catch insert 2004 may be similarly tapered toprevent the yarn catch insert 2004 from extending radially beyond thetop surface 2006 of the tube 2002 during winding operations.

The inner surfaces 2020, 2026 of the first and second members 2010, 2012are perpendicular to the longitudinal axis of the tube 2002 when theyare disposed in the hole 2008. In an exemplary embodiment, an adhesiveis applied to the outer surface 2034 of at least one of the first andsecond members 2010, 2012 to facilitate the process of grabbing the yarnduring a string-up procedure. Although the insert 2004 is shown in FIGS.20-23 as being inserted into a hole 2008 formed through a single tube2002, the insert may be inserted through two or more tubes in a similarfashion to that shown in FIGS. 19A-B for securing multiple tubestogether. With multiple tubes, the insert acts as a key as describedabove with reference to FIGS. 19A-B to mechanically link the tubestogether.

As shown in FIGS. 22-24, the edges 2038, 2040 at the top surface 2034 ofthe insert 2004 are radiused. The radiused edges 2040 adjacent to theside wall of the hole 2008 facilitate insertion of the insert 2004 intothe hole 2008. The radiused edges 2038 adjacent to the start-up groove1408 facilitate directing yarn into the start-up groove 1408.

An apparatus 2500 for forming a hole in a winding tube 2508 (shown inphantom) is shown in FIGS. 25-26. The hole to be formed is adapted toreceive a yarn catch insert. The apparatus 2500 includes a die 2502 anda punch 2504. The die 2502 has an opening 2506 formed therein forreceiving a punch 2504. The hole in the tube 2508 is formed by placingthe die 2502 within the tube 2508 and pressing the punch 2504, inalignment with the hole 2506 in the die 2502, through the tube 2508. Thedie 2502 has an outer surface 2510 that substantially matches thecurvature of at least a portion of the inner surface of the winding tube2508.

The outer surface of the die 2510 extends radially upward in thevicinity of the opening to form a lip 2512 as it approaches the opening2506. When the punch 2504 is pressed into a tube 2508 which is made of acompressible material, such as paper, while the die 2502 is in placeinside the tube 2508, the force exerted by the punch 2504 causes thetube 1508 to compress adjacent to the lip 2512 of the die 2502. Thiscompression forces forms a countersink into which the flange of a yarncatch insert is positioned as illustrated in FIG. 22.

Alternatively, when punching a hole through a paper tube that is tofunction as the outer tube of a multi-tube yarn carrier, the top surfaceof the die may match the curvature of the inside of the tube and nothave a lip in order to form a hole with sidewalls perpendicular to thelongitudinal axis of the tube. The inner tube in such a configurationmay include a countersink or other tapered shape for preventing the yarncatch insert from extending beyond the outer surface of the outer tube.In the case of the inner tube being a plastic tube, such a feature maybe molded, for example, into the inner tube.

A further variation of a yarn winding tube as contemplated by thepresent invention is shown in FIGS. 27 and 28, wherein the yarn catchgroove is provided in the inner layer of a multi-layer winding tube. Asillustrated, the yarn carrier 2900 includes an inner tube or core 2902,an outer tube or sleeve 2904, and a yarn catch groove 2906. The outertube 2904, preferably made of plastic or metal in this embodiment, isplaced on the inner tube 2902, preferably made of paper in thisembodiment, to form a composite yarn carrier. As illustrated, the yarncatch groove 2906 is formed in the outer surface of the inner tube 2902,which is inserted within the end of the outer tube 2904. The outer tube2904 has an opening 2908 formed therein so as to expose the yarn catchgroove 2906 (or other yarn catching mechanism, such as a separate moldedinsert). This composite design allows for the use of a paper tube forforming the yarn catch insert with the durability of a plastic outersleeve.

The replacement of inner tube structure is further facilitated by itsshortened structure which forms an insert for the end of the outer tube2904. The insert 2910 is inserted into the end of the outer tube 2904and abuts against a shoulder 2912 formed in the inside surface of theouter tube 2904. A rounded end 2918 is provided on the end of the insert2910, opposite the inserted end that abuts with the shoulder 2912. Asillustrated, the rounded end 2918 has a thickness that is greater thanthe wall thickness of the insert that forms the inner tubular portion2902. An inside surface of the rounded end 2918 forms a shoulder thatabuts against the end 2914 of the outer tube 2904.

The window 2908 is formed in the surface of the outer tube 2904 toprovide access to the startup groove 2906. The window 2908 has angledsidewalls to assist in directing the yarn into the grove and to assistin the transition of the yarn onto the winding surface of the outer tube2904. As shown in FIGS. 27 and 28, the winding startup groove is similarto that shown and described in the yarn carrier of FIGS. 14-18. However,it should be understood that an insert of the type shown and describedwith respect to FIGS. 19A and 19B or FIGS. 20-24 may be incorporatedinto the construction. Moreover, the materials of the inner and outertube may be varied as desired by the user. Again, the inner and outertubes are preferably manufactured in a manner to tightly position themagainst each other, and may be accomplished by any combination ofelements, including those previously described herein.

A further yarn carrier embodiment is shown in FIG. 29 and is identifiedgenerally by the numeral 3000. The yarn carrier 3000 includes an outeryarn winding tube 3002, an inner tube 3003 and a yarn catch insert 3004.In the present embodiment, it is contemplated that the inner tube 3003is substantially the same length as the outer tube 3002. As illustrated,a hole 3008 is provided in both the outer tube 3002 and inner tube 3003.The hole 3008 is asymmetrical and is formed such the two tubes 3002,3003 are brought into substantial registration by the insertion of thestartup insert 3004. As illustrated, the shape of the hole 3008 in thetwo tubes and the form of the insert are substantially the same as thatshown in FIGS. 20-24. The yarn catch insert 3004 is inserted into thehole 3008 from the inside of the inner tube 3003 and exposed to theouter yarn winding surface of the outer winding tube 3002. The insert3004 may also be removed from the hole 3008, with the first and secondmembers 3010, 3012 of the insert being separable to clean any yarnresidue from inside the groove 3014.

Although embodiments of the present invention are described above withregard to start-up grooves having particular dimensions, the teachingsof the present invention are applicable to a variety of types ofstart-up grooves. For example, inserts may be formed to create start-upgrooves for co-current winding or counter-current winding and with ourwithout barbs or hooks. Although some of the embodiments described abovehave a score and others do not, the particular embodiments are notlimited to having or not having a score.

The yarn carriers are shown in the Figures and described above as havinga single yarn catch insert. The teachings of present invention may beapplied to yarn carriers having multiple yarn catch inserts. A yarncarrier may include one or more yarn catch inserts on one side, on bothsides, or elsewhere in the winding tube of a yarn carrier. Further, asingle yarn carrier may be formed to create a bi-directional start-upgroove to allow winding in either a forward or a backward rotation byhaving a portion with a taper in one direction and a different portionwith a taper in an opposite direction. Also, multiple yarn catch insertsin a single yarn carrier may have different groove directionalorientations to allow for bi-directional use of the yarn carrier.

The foregoing describes the invention in terms of embodiments foreseenby the inventors for which an enabling description was available,notwithstanding that insubstantial modifications of the invention, notpresently foreseen, may nonetheless represent equivalents thereto.

1. A yarn catch insert for a yarn winding tube, the yarn winding tubeformed by a hollow tubular body having a longitudinal axis extendinglengthwise between first and second opposite ends, a substantiallycylindrical outer surface, and a circumferentially elongated holeextending through the tubular body from the inner hollow through to theouter surface, the yarn catch insert comprising: a. a first elongatedmember having a first end, a second end opposite the first end and aninner surface; and b. a second elongated member having a first end, asecond end and an inner surface facing the inner surface of the firstmember when the first and second members are positioned in the hole, astart-up groove formed between the inner surfaces of the first andsecond members, the start-up groove forming a tapered portion forcatching yarn therein.
 2. The yarn catch insert according to claim 1wherein the second end of the first member is coupled to the second endof the second member.
 3. The yarn catch insert according to claim 1wherein one of the first and second members has a barb extending beyondits inner surface toward the other member.
 4. The yarn catch insertaccording to claim 1 wherein the first and second members furthercomprise a bottom surface, a top surface and a flange extendingoutwardly from the bottom surface, the flange serving to fix theposition of the insert within the hole and prevent the top surface ofthe insert from extending past the outer surface of the tube.
 5. Theyarn catch insert according to claim 1 wherein the start-up groovetapers to a pinch point.
 6. The yarn catch insert according to claim 1wherein the start-up groove further comprises a widened portion adjacentthe tapered portion, the inner surfaces of the first and second membersin the widened portion being spaced from one another and substantiallyparallel.
 7. The yarn catch insert according to claim 1 furthercomprising an adhesive applied to an outside surface of at least one ofthe first and second members.
 8. A yarn carrier for winding yarn thereoncomprising: a. a hollow cylindrical winding tube having a longitudinalaxis extending lengthwise between first and second opposite ends, thetube having an outer cylindrical surface and an elongated hole formedthrough the tube, the hole completely surrounded by the cylindricalsurface and formed inwardly from the end of the tube, the elongateddimension of the hole extending in the circumferential direction of thetube; and b. a yarn catch insert positioned within the hole formedthrough the tube, the yarn catch insert comprising a first member havinga first end, a second end opposite the first end and an inner surface,and a second member having a first end, a second end and an innersurface, the inner surface of the second member facing the inner surfaceof the first member when the first and second members are positioned inthe hole, the inner surface of the first and second members forming ataper start-up groove within the outer surface of the tube.
 9. The yarncarrier according to claim 10 wherein the hole has a width that tapersin a direction from the inside to the outside surface of the tube andthe yarn catch insert comprises outer surfaces which conform to thetaper of the hole.
 10. The yarn carrier according to claim 10 whereinthe hole has a bulbous head at one end leading to a longitudinal sectionthat widens as it extends from the bulbous head.
 11. The yarn carrieraccording to claim 10 wherein the first ends of the first and secondmembers form a bulbous head on the yarn catch insert that conforms tothe bulbous head of the hole.
 12. The yarn carrier according to claim 11wherein the taper of the start up groove narrows toward the bulbousfirst end.
 13. The yarn carrier according to claim 8 wherein the firstends of the first and second members are tethered together.
 14. A yarncarrier according to claim 11 further comprising a second hollowcylindrical tube formed similar to the first mentioned winding tube, thesecond tube having an outer surface with a diameter that is less than aninner diameter of the first mentioned tube, the holes in the tubessimilarly formed and aligned when the tubes are co-axially positioned,and the insert positioned within the holes and fixing the overlappingalignment of the tubes.
 15. A yarn carrier for winding yarn thereoncomprising: a. a hollow cylindrical inner tube having a longitudinalaxis extending lengthwise between first and second opposite endsthereof, the tube having substantially cylindrical inner and outersurfaces and an elongated hole positioned radially inward of one end andextending through the tube wall from the inner surface to the outersurface along a portion of a circumference of the tube; b. a hollowcylindrical outer tube having a longitudinal axis extending lengthwisebetween first and second opposite ends thereof, the outer tube having asubstantially cylindrical inner surface with a diameter that is greaterthan the diameter of the outer surface of the inner tube, and anelongated hole formed through the outer tube along a portion of acircumference of the tube, wherein the inner tube is disposed within theouter tube and wherein the holes in the inner and outer tubes aresubstantially aligned; and c. a yarn catch insert accordingly positionedwithin the holes in the inner and outer tubes, the yarn catch insertcomprising a first end, a second end opposite the first end, and atapered start-up groove formed in a central portion of the insert.
 16. Ayarn carrier according to claim 15 wherein the outer surface of theinner tube comprises ribs for securing the outer tube to the inner tube.17. A yarn carrier according to claim 15 wherein the inner and outertubes comprise plastic, metal, wood or combinations thereof.
 18. A yarncarrier according to claim 15 wherein the outer tube comprises paper.19. The yarn carrier according to claim 14 wherein the insert comprises:a first member having a first end, a second end and an inner surface,and a second member having a first end, a second end and an innersurface, the first and second members positioned adjacent one another toform the insert and the inner surfaces of the first and second membersaligned to form opposite sides of the tapered start-up groove.
 20. Theyarn carrier according to claim 19 wherein the first ends of the firstand second members are tethered together.
 21. The yarn carrier accordingto claim 15 wherein the first end of the insert comprises a bulbous headpositioned at the end of the tapered portion of the start-up groove. 22.The yarn carrier according to claim 21 wherein the start-up groovefurther comprises a widened portion adjacent the tapered portion,opposite the bulbous head.